CN108637448A - A kind of monitoring method of dissimilar metal ultrasonic bonding edge crack - Google Patents

A kind of monitoring method of dissimilar metal ultrasonic bonding edge crack Download PDF

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Publication number
CN108637448A
CN108637448A CN201810309832.XA CN201810309832A CN108637448A CN 108637448 A CN108637448 A CN 108637448A CN 201810309832 A CN201810309832 A CN 201810309832A CN 108637448 A CN108637448 A CN 108637448A
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China
Prior art keywords
ultrasonic
welding
ultrasonic power
power curve
edge crack
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CN201810309832.XA
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CN108637448B (en
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曹彪
柳健
杨凯
吴敏
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South China University of Technology SCUT
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South China University of Technology SCUT
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K20/00Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/10Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating making use of vibrations, e.g. ultrasonic welding
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K31/00Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups
    • B23K31/12Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups relating to investigating the properties, e.g. the weldability, of materials
    • B23K31/125Weld quality monitoring

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Quality & Reliability (AREA)
  • Pressure Welding/Diffusion-Bonding (AREA)
  • Investigating Or Analyzing Materials By The Use Of Ultrasonic Waves (AREA)

Abstract

The invention discloses a kind of monitoring methods of dissimilar metal ultrasonic bonding edge crack;Include the following steps:Through data collecting card acquisition transducer current, voltage signal, the envelope of current and voltage signals is sought, in conjunction with the phase difference of current signal and voltage signal, calculates the ultrasonic power curve P (t) for obtaining welding process.Smooth ultrasonic power curve Q (n) is obtained after being smoothed to ultrasonic power curve P (t) using moving average filter.Then the change rate K for seeking smooth ultrasonic power curve each point successively, when its change rate K is more than threshold value D, then welding region non-flanged crackle generates during may determine that ultrasonic bonding;When change rate K be less than or equal to threshold value D, then can determine that edge crack occurs in welding region.

Description

A kind of monitoring method of dissimilar metal ultrasonic bonding edge crack
Technical field
The present invention relates to ultrasonic wave metal welding technology fields more particularly to a kind of dissimilar metal ultrasonic bonding edge to split The monitoring method of line.
Background technology
Ultrasonic wave metal welding has welding interval as a kind of high-quality, efficient, low consumption and clean solid phase joining technique Short, weld interface temperature is low, be not necessarily to scaling powder and low energy consumption the advantages that.Ultrasonic wave metal welding technique is in dissimilar metal at present As copper/aluminium, steel/aluminium and magnesium/aluminium etc. obtain in-depth study and is widely applied in connection.
In the connection procedure of dissimilar metal, the tensile strength of welding point generally first increases with weld interval/welding energy, After reaching maximum value, due to excessively thickening and the extension of crackle, tensile strength continuously decrease for intermetallic compound.Correlation is ground Study carefully the result shows that in aluminium/copper, aluminium/galvanized steel plain sheet and aluminium/Low-carbon Steel by Ultrasonic welding process, energy to fracture reaches maximum value When, there is crackle in welding region edge.In order to obtain the welding point of high-tensile as far as possible, should as far as possible use most Excellent parameter.But ultrasonic welding method is very sensitive to welding condition, many extraneous factors meeting welding qualities cause Harmful effect causes the generation of weld defect such as edge crack.With the development of high power altrasonic welder, supersonic welding is connected on The connection area of dissimilar metal will be widely used.In actual production, ensures that and obtain high intensity and solderless The connector for connecing defect also needs a kind of online edge crack monitoring method other than obtaining best welding parameter, and rejecting, which has, to be split The welding point of line defect.
Invention content
The shortcomings that it is an object of the invention to overcome the above-mentioned prior art and deficiency provide a kind of dissimilar metal supersonic welding Connect the monitoring method of edge crack, it is ensured that obtain the connector of high intensity and welding defect.
The present invention is achieved through the following technical solutions:
(1) the ultrasonic power P (t) of welding process is obtained in real time:
Ultrasonic electric current is measured by current transformer, electric resistance partial pressure measures ultrasonic voltage, and is acquired through data collecting card Transducer current and voltage signal seek the envelope of current signal and the envelope of voltage signal.By obtained current signal It is utilized in conjunction with the phase difference of current signal and voltage signal with the envelope of voltage signalCalculate the ultrasonic power P (t) of welding process.Wherein U (t) is transducer voltage Signal;I (t) is transducer current signal;For the phase difference of transducer current signal and voltage signal.
(2) smoothing processing of ultrasonic power curve:
Convert ultrasonic power discrete point P (t) to column vector, the window width of moving average filter is set as N, is put down using mobile Equal filter, which is smoothed column vector, obtains smooth ultrasonic power curve.Wherein smooth ultrasonic power Q (t) is
(3) determination of threshold value:
For corresponding welding workpiece, under normal welding condition, and the condition of weld interval is appropriately extended Under, carry out multiple welding.Test obtains normal weld and corresponding power curve of different extension times, and is carried out to power curve After smoothing processing, the change rate of ultrasonic power curve each point is sought, and the corresponding change rate of knick point power curve will be played and be used as and split The threshold value D of line determining defects.
(4) judge to weld the process whether sample cracks:
Determine that the variation of ultrasonic power change rate generates the two with edge crack in conjunction with Welding experiment and theory deduction Between relationship;The rate of change value of ultrasonic power curve is all more than threshold value after smoothed processing, then welds the generation of sample flawless;Its When rate of change value occurs being less than or equal to threshold value, welding region edge cracks.
The present invention compared with the existing technology, has the following advantages and effect:
(1) it is directed to the variation of ultrasonic weld joints quality welding parameters or process conditions (such as thickness of workpiece) very Sensitive issue, the inner link between being generated according to the variation of power curve and edge crack, is realized to welding edge marginal slit line Automatic on-line monitoring and evaluation, reduce manpower and materials consumption, ensure joint quality.
(2) after welding parameters optimize, in conjunction with the monitoring method, it both ensure that welding point welding defect was produced It is raw, also ensure the high intensity of the welding point.
Description of the drawings
Fig. 1 is the flow chart of the monitoring method of dissimilar metal ultrasonic bonding edge crack of the present invention.
Fig. 2 is the schematic diagram of ultrasonic metal welding procedural information acquisition analysis system structure in the embodiment of the present invention.
Fig. 3 is transducer drive current in the embodiment of the present invention, the schematic diagram of driving voltage Acquisition Circuit.
Fig. 4 is that amplitude is set as 80% in the embodiment of the present invention, and crackle generates front and back micro- knot during ultrasonic bonding Structure.
Fig. 5 is in the embodiment of the present invention under the conditions of various amplitude, and edge crack generates front and back ultrasonic power curve.
Fig. 6 is the stress diagram of soldering tip in the embodiment of the present invention under crackle Production conditions.
Fig. 7 is smoothed treated ultrasonic power curve in the embodiment of the present invention.
Fig. 8 is the corresponding change rate variation of ultrasonic power after smoothing processing in the embodiment of the present invention under the conditions of various amplitude Curve.
Specific implementation mode
The present invention is more specifically described in detail with reference to specific embodiment.
The present embodiment carries out Welding experiment to C1100 fine copper plate and Al5652 aluminium alloys, and welded specimen dimensions is: 70mm × 25mm × 0.8mm, without any surface treatment before sample welding.Sample is placed on chopping block and is welded, welding Connector is joint form, lap of splice 25mm, and copper coin is placed on aluminium sample;Limited block is installed on chopping block, prevents from welding Sample ensures that solder joint is located at overlapping regions center due to the larger offset of vibrations generation of tool heads in journey.
By obtaining electric current, the voltage signal of energy converter, judge whether welding point generates edge crack, key step is such as Under:
(1) ultrasonic power of welding process is obtained in real time
The system structure of the electric current and voltage signal of energy converter is acquired in welding process, as shown in Figure 2.Select Current Mutual Inductance Device measures ultrasonic electric current, and electric resistance partial pressure measures ultrasonic voltage, the signal that each sensor obtains after signal conditioning circuit is handled, It is converted into the voltage signal of 0~10V, then uses data collecting card NI-6133 to acquire corresponding signal, Acquisition Circuit is as schemed Shown in 3.Electric current, the amplitude envelope line of voltage signal and its corresponding phase difference are found out, and then calculates the ultrasound of welding process Power P (t).
(2) relationship and its reason that power curve variation is generated with edge crack are determined
When amplitude is set as 80%, when weld interval is 1.1s, there is the isomerizing zone of part in interface, but does not split Line, as shown in Fig. 4 (a);When weld interval is 1.2s, crackle generates, and the as shown in Fig. 4 (b) is 90% and 100% in amplitude When, it is observed that similar phenomenon.When amplitude is 90%, 0.7s does not have found that crackle, 0.8s crackles generate;Amplitude is 100% When, 0.3s is not cracked, and 0.4s crackles occur.When amplitude is 80%, when weld interval is 1.1s, power curve is not shown Write the phenomenon that declining;With the generation of edge crack, when weld interval is 1.2s, power curve is in 1.1s~1.2s time sections Appearance is remarkably decreased amplitudes and was set as 90% weld interval when being 0.7s, the phenomenon that power curve is not remarkably decreased;When welding Between when being 0.8s, edge crack generates, while power curve is remarkably decreased in 0.7s~0.8s time sections.Amplitude is set as 100%, when weld interval is 0.3s, the phenomenon that power curve is not remarkably decreased;When weld interval is 0.4s, it can observe To edge crack, and power curve is remarkably decreased in 0.3s~0.4s, as shown in Figure 5.By ultrasonic bonding test with And below known to theory deduction, ultrasonic power curve occurs being remarkably decreased with the generation of welding region edge crack
Its concrete reason is analyzed as follows
Ultrasonic power and the relationship of soldering tip shearing force are as follows:
P=Fs*vavg (1)
Wherein P is the mean power in a vibration period;FsFor soldering tip shearing force;vavgFor soldering tip average movement velocity.
It measures and understands through laser displacement sensor, the moving displacement of soldering tip can be expressed as
ξ (t)=ξ0Sin (ω t), f=| ω |/2 π (f=20kHz) (2)
Wherein ξ0For amplitude;ω is angular speed;F is ultrasonic vibration frequency.
Displacement derivation to soldering tip, certain a moment soldering tip movement speed are represented by
It differentiates again to soldering tip movement speed, then the translational acceleration of certain a moment soldering tip is
In signal period, the average movement speed of soldering tip is
Wherein T is the vibration period.
Formula (5) is substituted into formula (1), can be obtained
P=Fs*4*ξ0*f (6)
It can be obtained according to Newton's second law by Fig. 6
Wherein m is welding head quality, FIFor the frictional resistance by bit copper plate to soldering tip, F is by bit copper plate to the transverse direction of soldering tip Deformation drag.
By formula (7), soldering tip shearing force is represented by
From formula (6), ultrasonic power is dependent only on soldering tip shearing force, Oscillation Amplitude and vibration frequency vibration frequencies Rate is the generation of 20kHz. crackles, causes internal stress to redistribute, FLIs strongly reduced from formula (8), in identical amplitude Under the conditions of, FLIt strongly reduces, leads to soldering tip shearing force FSThe feedback control system for strongly reducing supersonic welders is changed by adjusting The output power of energy device ensures soldering tip and makees high frequency periodic to set amplitude and frequency and move since the generation of crackle causes to weld Shearing force is substantially reduced, so required ultrasonic power is substantially reduced, the real-time adjusting through reponse system, under power curve is notable Drop.
(3) smoothing processing of ultrasonic power curve
There are certain ripples for the ultrasonic power curve of DATA REASONING, are unfavorable for the identification of ultrasonic power changing rule, because This needs to be smoothed it.It is 100% by amplitude, weld interval is respectively 0.3s and 0.4s;Amplitude is 90%, welding Time is respectively 0.7s and 0.8s;Amplitude is 80%, and weld interval is respectively the corresponding ultrasonic power dispersion numbers of 1.1s and 1.2s Strong point P (t) imports the workspace in matlab, and the original power curve of acquisition is as shown in Figure 5.Pass through function smooth (P (t), 9), ultrasonic power curve is smoothed, obtains smooth power curve Q (t), as shown in Figure 7.
(4) calculating of power curve change rate
By treated, the corresponding discrete data point Q (t) of power curve is imported in a manner of vector in matlab Workspace, while by its corresponding weld interval tnThe workspace in matlab is imported in a manner of vector, Command Window input K=gradient (Q (t)) ./gradient (tn), you can it is corresponding under the conditions of acquisition various amplitude The change rate curve of power after smoothing processing, as shown in Figure 8.
(5) determination of threshold value
In the case where amplitude is 100% 90% and 80%, 0.3s repeatedly carried out to copper coin and aluminium sheet respectively, 0.7s and The welding of 1.2s, will suitably extend 0.1s weld intervals, and welding point starts to crack.Extract the ultrasonic work(under each welding condition Rate curve is smoothed it and calculates the corresponding change rate of smooth power curve each point successively.As shown in Figure 8, Under conditions of amplitude is 100%, 90% and 80%, flawless generates corresponding power variation rate minimum value KminRespectively- 2600, -1800, -1000. when having crackle generation, corresponding power variation rate minimum value Kmin2Respectively -13333, -8900, - In 3500. examples, the corresponding change rate of knick point power curve is that -3500. corresponding threshold value D are -3500, and the threshold value is big The corresponding minimum value of power variation rate when cracking can effectively reject the welding point of crackle generation.
(6) whether judgement sample cracks
It according to the relationship between predetermined edge crack and power curve, can obtain, when power variation rate K is more than threshold value When D, then welding region flawless phenomenon during ultrasonic bonding can be determined;When change rate K be less than or equal to threshold value D, Power curve is remarkably decreased, then may determine that edge crack centainly occurs in welding region.
The method of the present invention finds that edge is split by the experiment of a large amount of ultrasonic wave dissimilar metal welding and theoretical validation first The generation of line can lead to being remarkably decreased for power curve, then determine that a threshold value D, threshold value reflection power curve reach certain Decline degree when, edge crack has generated.Specific embodiment is:Electric current, the voltage signal of extraction of transducer, Jin Erji Calculate and obtain the ultrasonic power curve P (t) of welding process;It is smoothed, it is each then to find out corresponding smoothed curve The change rate of discrete point, when required change rate K values are more than D, then it is 1 to export result, and welding sample flawless generates, corresponding product For qualification;When required change rate K values are less than or equal to D, then it is 0 to export result, and welding sample has edge crack generation, corresponding production Product are unqualified.
The present invention is suitable for the quality-monitoring of dissimilar metal ultrasonic bonding, after a large amount of soldering test, it has been determined that Its optimal welding parameter, but the variation of the quality welding parameters or process conditions (such as thickness of workpiece) due to welding point Very sensitive, some slight variations may also lead to the generation of weld defect, and edge crack and ultrasonic power curve are directed in text Relationship, establish a kind of crack monitoring method, be conducive to obtain high intensity, the dissimilar metal welding connector of flawless defect.
The present invention is welded applied to ultrasonic wave metal, may be implemented that the automatic on-line of welding edge marginal slit line is monitored and commented Estimate, reduces manpower and materials consumption, ensure joint quality.
As described above, the present invention can be better realized.
Embodiment of the present invention are not limited by the above embodiments, other any Spirit Essences without departing from the present invention With under principle made by changes, modifications, substitutions, combinations, simplifications, should be equivalent substitute mode, be included in the present invention Within protection domain.

Claims (5)

1. a kind of monitoring method of dissimilar metal ultrasonic bonding edge crack, which is characterized in that include the following steps:
The ultrasonic power P (t) of welding process is obtained in real time;
Ultrasonic power P (t) is smoothed;
Successively calculate smoothing processing after ultrasonic power change rate;
Judge whether the rate of change value of power curve is more than threshold value, if so, welding sample flawless generates;If it is not, then welding Sample has edge crack generation.
2. the monitoring method of dissimilar metal ultrasonic bonding edge crack according to claim 1, which is characterized in that obtain in real time Ultrasonic power P (t) processes of welding process are taken to include:
Ultrasonic electric current is measured by current transformer, electric resistance partial pressure measures ultrasonic voltage, and acquires transducing through data collecting card Device electric current and voltage signal calculate the envelope for obtaining electric current and voltage signal, in conjunction with the phase of current signal and voltage signal Difference, and then utilizeCalculate the ultrasonic power P (t) in welding process;
Wherein U (t) is transducer voltage signal;I (t) is transducer current signal;For transducer current signal and voltage The phase difference of signal.
3. the monitoring method of dissimilar metal ultrasonic bonding edge crack according to claim 1, which is characterized in that obtain institute The smoothing processing for stating ultrasonic power P (t) includes:
Convert ultrasonic power discrete point P (t) to vector, the window width of moving average filter is set as N, utilizes moving average filtering Device obtains smooth ultrasonic power Q (t) after being smoothed to the vector.
4. the monitoring method of dissimilar metal ultrasonic bonding edge crack according to claim 1, which is characterized in that at calculating The change rate of ultrasonic power after reason includes:
It utilizesThe change rate of smooth ultrasonic power is sought successively;
Wherein Q (t) is corresponding value after ultrasonic power P (t) smoothing processings.
5. the monitoring method of dissimilar metal ultrasonic bonding edge crack according to claim 1, which is characterized in that threshold value Determination includes:
For corresponding welding workpiece, under conventional welding condition, and extends under conditions of weld interval, carry out more Secondary welding;
Test obtains normal welding and corresponding power curve of different extension times, and after being smoothed to power curve, Seek the change rate of ultrasonic power curve each point;Relationship between observation and determining connector crackle and power curve slippage, and The threshold value D judged the corresponding change rate of knick point power curve is played as crack defect.
CN201810309832.XA 2018-04-09 2018-04-09 Method for monitoring heterogeneous metal ultrasonic welding edge cracks Expired - Fee Related CN108637448B (en)

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Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4746051A (en) * 1982-12-08 1988-05-24 General Motors Corporation Ultrasonic welding control
US5855706A (en) * 1992-04-21 1999-01-05 Branson Ultrasonics Corporation Simultaneous amplitude and force profiling during ultrasonic welding of thermoplastic workpieces
JP2001070883A (en) * 1999-09-06 2001-03-21 Matsushita Electric Ind Co Ltd Abnormality detector of ultrasonic vibrator transducer and abnormality detection therefor
JP2007289996A (en) * 2006-04-25 2007-11-08 Arutekusu:Kk Ultrasonic welder
CN101075569A (en) * 2006-05-18 2007-11-21 中南大学 Method for loading bonding parameter
CN101073851A (en) * 2006-05-18 2007-11-21 中南大学 System for monitoring and analyzing energy exchanger of thermal-ultrasonic reversed bonding machine
FR2916665A1 (en) * 2007-05-29 2008-12-05 Valeo Electronique Sys Liaison METHOD AND DEVICE FOR WELDING A BUS BAR AND CABLES
CN101594963A (en) * 2006-09-16 2009-12-02 申克索诺***有限责任公司 Be used for when ultrasonic bonding, carrying out the method for quality-monitoring
CN107175399A (en) * 2017-04-05 2017-09-19 珠海市新维焊接器材有限公司 The welding method of supersonic welder

Patent Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4746051A (en) * 1982-12-08 1988-05-24 General Motors Corporation Ultrasonic welding control
US5855706A (en) * 1992-04-21 1999-01-05 Branson Ultrasonics Corporation Simultaneous amplitude and force profiling during ultrasonic welding of thermoplastic workpieces
JP2001070883A (en) * 1999-09-06 2001-03-21 Matsushita Electric Ind Co Ltd Abnormality detector of ultrasonic vibrator transducer and abnormality detection therefor
JP2007289996A (en) * 2006-04-25 2007-11-08 Arutekusu:Kk Ultrasonic welder
CN101075569A (en) * 2006-05-18 2007-11-21 中南大学 Method for loading bonding parameter
CN101073851A (en) * 2006-05-18 2007-11-21 中南大学 System for monitoring and analyzing energy exchanger of thermal-ultrasonic reversed bonding machine
CN101594963A (en) * 2006-09-16 2009-12-02 申克索诺***有限责任公司 Be used for when ultrasonic bonding, carrying out the method for quality-monitoring
FR2916665A1 (en) * 2007-05-29 2008-12-05 Valeo Electronique Sys Liaison METHOD AND DEVICE FOR WELDING A BUS BAR AND CABLES
CN107175399A (en) * 2017-04-05 2017-09-19 珠海市新维焊接器材有限公司 The welding method of supersonic welder

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